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Table of Contents
PEOPLE/PEOPLE S 250
By KWANG YANG Motor Co., Ltd.
First Edition, Jan 2006
All rights reserved. Any reproduction or
unauthorized use without the written
permission of KWANG YANG Motor Co., Ltd.
is expressly prohibited.
4122-LLJ3/LDH1-S00

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Table of Contents

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   Summary of Contents for KYMCO People

  • Page 1 PEOPLE/PEOPLE S 250 By KWANG YANG Motor Co., Ltd. First Edition, Jan 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. 4122-LLJ3/LDH1-S00...
  • Page 2: Table Of Contents

    PEOPLE/PEOPLE S 250 PREFACE TABLE OF CONTENTS This Service Manual describes the technical features and servicing GENERAL INFORMATION procedures for the KYMCO People/People s 250. EXHAUST MUFFLER/FRAME COVERS INSPECTION/ADJUSTMENT Section 1 contains the precautions for all operations stated in this LUBRICATION SYSTEM manual.
  • Page 3: General Information

    1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ SERIAL NUMBER ------------------------------------------------------------------------------------ 1-1 SPECIFICATION ------------------------------------------------------------------------------------- 1-2 SERVICE PRECAUTIONS ------------------------------------------------------------------------- 1-4 TORQUE VALUES ----------------------------------------------------------------------------------- 1-8 SPECIAL TOOLS ------------------------------------------------------------------------------------- 1-9 LUBRICATION POINTS -------------------------------------------------------------------------- 1-10 CABLE & HARNESS ROUTING------------------------------------------------------------------- 1-12...
  • Page 4: General Information

    1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...
  • Page 5: Specification

    1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 SPECIFICATIONS Name & Model No. BC50AA Air cleaner type & No Paper element, wet Motorcycle Name & Type PEOPLE 250 Fuel capacity 8.5 liters Overall length 2130mm Type Overall width 750mm Piston dia. Overall height 1170mm Venturi dia.
  • Page 6 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 SPECIFICATIONS Name & Model No. BA50AA Air cleaner type & No Paper element, wet Motorcycle Name & Type PEOPLE S 250 Fuel capacity 10.0 liters Overall length 2140mm Type Overall width 750mm Piston dia.
  • Page 7: Service Precautions

    1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 „ Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication points. „ Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. „ After reassembly, check all parts for proper tightening and operation.
  • Page 8 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 „ If the fuse is burned out, find the cause and „ The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. „ If the double connector has a lock, lock it at the correct position.
  • Page 9 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 „ After clamping, check each wire to make „ Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not pull too tight „ Do not squeeze wires against the weld or its clamp.
  • Page 10 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 „ After routing, check that the wire harnesses „ Symbols: are not twisted or kinked. The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points.
  • Page 11: Torque Values

    1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (N-m) Item Torque (N-m) 5mm bolt, nut 4.5 6 5mm screw 3.5 5 6mm bolt, nut 8 12 6mm screw, SH bolt 7 11 8mm bolt, nut...
  • Page 12: Special Tools

    1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 FRAME Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks Steering stem lock nut 40 50 Front axle nut 60 70 Rear axle nut 110 130 Rear shock absorber upper bolt 35 45 Rear shock absorber lower bolt...
  • Page 13: Lubrication Points

    PEOPLE/PEOPLE S 250 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part xGenuine KYMCO Engine Oil (SAE15W-40) Camshaft protruding surface xAPI SE, SF or SG Egnine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut...
  • Page 14 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.
  • Page 15: Cable & Harness Routing

    1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 CABLE & HARNESS ROUTING Front Brake Master Cylinder Winker/Horn/DIM Wire Rear Brake Master Cylinder Speedometer Cable Throttle Cable Rear Brake Fluid Tube Front Brake Fluid Tube Horn Radiator Air Ventilated Tube (to Radiator) Fuel Tank Cap...
  • Page 16 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 Start/Light/ENG Stop/Passing Wire Winker/Horn/DIM Wire Radiator Cap Water Duct Hose Radiator Air Ventilated Radiator Tube (to Radiator Water Duct) Fuel Tank Cap Thermostatic Switch Radiator Air Ventilated Tube Water Inlet Hose Fuel Tank Water Outlet Hose...
  • Page 17 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 Winker/Horn/DIM Wire Start/Light/ENG Stop/Passing Wire Radiator Air Ventilated Tube (to Raciator) Throttle Cable Front Brake Fluid Tube Radiator Air Ignition Switch Ventilated Tube Water Inlet Hose Fuel Tank Cap Fan Motor Wire Rear Brake Fluid...
  • Page 18 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 Secondary Air Vacuum Tube Fuel Tank Inlet Tube Thermostat Wire Harness Thermosensor Wire Fuel Pump Vacuum Tube Starter Motor wire Heater Wire Starter Relay Air Inlet Hose (V-belt Chamber) Ignition Coil Battery (+) Cable Fuse Box A.C.G/Starter...
  • Page 19 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 Starter Relay Heater Control Unit Carburetor Fuel Pump Ignition Coil Oil Vapor Recovery Tube Secondary Air Inlet Tube Spark Cap Side Stand Switch Fuel Unit Wire Harness 1-16...
  • Page 20 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 Battery Fuse Box Ignition Coil Starter Motor Carburetor Wire Regulator/ Rectifier Fuel Unit Secondary Air Cleaner Fresh Air Inlet Hose Secondary Air Cleaner Fuel Pump Secondary Air Cleaner Fresh Air Outlet Hose Fuel Tube (Between Fuel Pump and Fuel Filler)
  • Page 21 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 Battery Battery (+) Cable Battery (-) Cable Fuse Box Ignition Unit Rear Brake Caliper Seat Open Cable Starter Relay Ignition Coil Throttle Cable Wire Harness Rear Brake Fluid Tube Carburetor Auto Bystarter Thermostat T.P.S...
  • Page 22 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 People s 250 model Battery Fuse Box Ignition Coil Starter Motor Wire Carburetor Regulator/ Rectifier Fuel Cap Fuel Pump Fuel Tube (Between Fuel Pump and Fuel Filler) Secondary Air Cleaner Fresh Air Outlet Hose Starter Relay C.D.l Unit...
  • Page 23: Wiring Diagram

    1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 WIRING DIAGRAM (PEOPLE 250) 1-20...
  • Page 24 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 WIRING DIAGRAM (PEOPLE S 250) 1-21...
  • Page 25: Troubleshooting

    1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw cEmpty fuel tank dClogged carburetor fuel inlet tube, vacuum tube or fuel tube...
  • Page 26: Inspection/adjustment

    1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and cClogged air cleaner accelerate lightly for dRestricted fuel flow observation eClogged fuel line between fuel tank and carburetor Engine speed does Engine speed fClogged exhaust muffler...
  • Page 27 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing cFaulty ignition unit Incorrect timing Correct timing dFaulty A.C. generator Check carburetor pilot screw adjustment cMixture too rich (turn screw...
  • Page 28 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing cFaulty ignition unit Correct timing Incorrect timing dFaulty A.C. generator Check valve clearance cImproperly adjusted valve Correctly adjusted Incorrectly adjusted clearance dWorn valve seat...
  • Page 29 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 ENGINE NOISE Symptom Probable Cause cValve clearance too large Valve noise dWorn camshaft lobe cWorn piston rings dWorn piston pin and connecting rod small Piston noise eExcessive carbon build-up in combustion chamber cDamaged cam chain tensioner...
  • Page 30 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause cWorn or slipping drive belt dBroken ramp plate eBroken drive face spring Engine starts but fSeparated clutch lining motor-cycle does not gDamaged driven pulley shaft splines...
  • Page 31 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of stop switch by cBurned out fuse applying brake dWeak or dead battery Stoplight does not eFaulty stop switch Stoplight comes on...
  • Page 32 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark cFaulty spark plug Check spark plug cap and high-tension wire...
  • Page 33 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals cFaulty AC generator Voltage does not Normal voltage dFaulty regulator/rectifier increase eFaulty battery...
  • Page 34 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Probable Cause Inspection/Adjustment Symptom Check battery circuit by operating turn signals cBurned out fuse dWeak or dead battery Signals operate Signals dim, remain...
  • Page 35 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) cSteering stem nut too tight Steering is heavy dBroken steering steel balls cExcessive wheel bearing play Front or rear wheel is...
  • Page 36 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS ________________________________________________________________________________ SCHEMATIC DRAWING----------------------------------------------------------------------------- 2-1 SERVICE INFORMATION--------------------------------------------------------------------------- 2-2 TROUBLESHOOTING ------------------------------------------------------------------------------- 2-3 FRAME COVERS REMOVAL ------------------------------------------------------------------ 2-4,12 EXHAUST MUFFLER REMOVAL -------------------------------------------------------------2-10,16...
  • Page 37: Schematic Drawing

    2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING...
  • Page 38 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 PEOPLE S 250...
  • Page 39: Service Information

    2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. x Make sure to route cables and harnesses according to the Cable & Harness Routing.
  • Page 40: Frame Covers Removal

    2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 FRAME COVERS REMOVAL RIGHT AND LEFT BACK MIRROR REMOVAL Loosen the nut on the back mirror. Remove the back mirror. Nuts HANDLEBAR FRONT COVER REMOVAL Remove one bolt on the handlebar front cover.
  • Page 41 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 Handlebar Rear Cover HANDLEBAR REAR COVER REMOVAL Remove handlebar front cover. ( Ö 2-3) Remove front cover. ( Ö2-4 ) Remove the bolt on the handlebar rear cover. Blot Remove the two screws attaching frame.
  • Page 42 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 Remove the four screws attaching the front under cover. Disconnect the front cover from leg shield and front under cover. Screws Disconnect all of the wire couplers. Wire Couplers Remove the front cover.
  • Page 43 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 RIGHT/LEFT SIDE COVER REMOVAL Remove the screw combine right (left) side cover with front under cover. Remove the screw combine right (left) side cover with the floor board. Remove the right (left) side cover.
  • Page 44 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 Screws Screws Remove the met-in box and rear carrier. ( Ö2- Remove the four screws attaching the floor board. Remove the two screws on the rear fender A. Screws Wire Couplers Disconnect all of the wire couplers.
  • Page 45 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 FRONT UNDER COVER REMOVAL Screw Screw Remove the front cover. ( Ö2-8 ) Remove the right and left side cover. ( Ö2-6 ) Remove the two screws that combine the front under cover with the leg shield.
  • Page 46 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 Bolts Remove the center under cover. Under Cover Screws REAR FENDER COVER B/C REMOVAL Remove the met-in box. ( Ö2-6 ) Remove the body cover, center cover and rear fender A together. ( Ö2-6 ) Remove the four screws on the rear fender B.
  • Page 47: Exhaust Muffler Removal

    2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 Rear Fender Cover C Air Clean Case Remove the screw attaching the air cleaner case. Remove the rear fender C. Screws Joint Lock Nuts EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts.
  • Page 48 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 Bolts FRAME COVERS REMOVAL REAR CARRIER Remove the met-in box. First remove the four bolts attaching the met- in box. Remove the met-in box. Carrier Remove the three bolts attaching the rear carrier.
  • Page 49 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 Side Cover SIDE COVER REMOVAL Remove the screws attaching the right and left side covers. Remove the right and left side covers by pulling them outward. Screws Center Disconnect the tow screws attaching the center cover.
  • Page 50 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 Remove the front cover of decoration cover. Decoration Cover Removes the decoration covers by the little tool push the decoration of a back claw. Tool Remove the bolt on the front cover. Bolt...
  • Page 51 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 Bolt LEG SHIELD COVER REMOVE Remove the ignition switch decoration ring. Remove the bolt on the leg shield cover. Remove the two screws on the back of under position. Disconnect the leg shield cover.
  • Page 52 2. EXHAUST MUFFLER/FRAME COVERS PEOPLE/PEOPLE S 250 Bolt HANDLEBAR COVER REMOVAL First remove the windshield. Remove the four screws and two bolts attaching the handlebar rear cover. Remove the handlebar rear cover. The installation sequence is the reverse of removal.
  • Page 53 3. INSPECTION/ADJUSTMENT PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ INSPECTION/ADJUSTMENT ________________________________________________________________________________ SERVICE INFORMATION----------------------------------------------------------------------- 3- 1 MAINTENANCE SCHEDULE------------------------------------------------------------------- 3- 2 FUEL LINE/FUEL FILTER----------------------------------------------------------------------- 3- 3 THROTTLE OPERATION ----------------------------------------------------------------------- 3- 3 ENGINE OIL ---------------------------------------------------------------------------------------- 3- 4 AIR CLEANER ------------------------------------------------------------------------------------- 3- 5...
  • Page 54: Service Information

    2 Riders Front 1.75kg/cm² 1.75kg/cm² Rear 2.0kg/cm² 2.0kg/cm² TIRE SPECIFICATION: Front : 110/70-16 52P Rear : 140/70-16 65P TORQUE VALUES Front axle : 29 35N-m Front axle nut : 60 70N-m (people s 250) Rear axle nut : 110 130N-m...
  • Page 55: Maintenance Schedule

    Brake lever Brake shoe wear Shock absorber x In the interest of safety, we recommend these items be serviced only by an authorized KYMCO motorcycle dealer. Note: 1. For higher odometer readings, repeat at the frequency interval established here. 2. Service more frequently when riding in dusty or rainy areas.
  • Page 56: Fuel Line/fuel Filter

    3. INSPECTION/ADJUSTMENT PEOPLE/PEOPLE S 250 Fuel Filter FUEL LINE/FUEL FILTER Remove the right side cover. Check the fuel lines and replace any parts, which show signs of deterioration, damage or leakage. Check for dirty or clogged fuel filter and replace with a new one if it is clogged.
  • Page 57: Engine Oil

    3. INSPECTION/ADJUSTMENT PEOPLE/PEOPLE S 250 Oil Dipstick ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the scooter upright on level ground. Wait for 2 3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when making this check.
  • Page 58: Air Cleaner

    3. INSPECTION/ADJUSTMENT PEOPLE/PEOPLE S 250 Air Cleaner Case Cover AIR CLEANER Remove the six air cleaner case cover screws and the cover. Screws Air Cleaner Element Remove the air cleaner element. Check the element and replace it if it is excessively dirty or damaged.
  • Page 59: Valve Clearance

    3. INSPECTION/ADJUSTMENT PEOPLE/PEOPLE S 250 Cylinder Head Cover Upper Bolts VALVE CLEARANCE x Inspect and adjust valve clearance while the engine is cold (below 35 ). Remove the met-in box and center cover. Disconnect oil vapor recovery tube and secondary air cleaner fresh air outlet hose from cylinder head cover.
  • Page 60: Cylinder Compression

    3. INSPECTION/ADJUSTMENT PEOPLE/PEOPLE S 250 CYLINDER COMPRESSION Warm up the engine before compression test. Remove the center cover and spark plug cap. Remove the spark plug. Insert a compression gauge. Open the throttle valves fully and pushes the starter button to test the compression.
  • Page 61: Final Reduction Gear Oil

    3. INSPECTION/ADJUSTMENT PEOPLE/PEOPLE S 250 Oil Check Bolt Hole/Oil Filler FINAL REDUCTION GEAR OIL x Place the scooter on its main stand on level ground. Stop the engine and remove the oil checks bolt. The oil level shall be at the oil check blowhole.
  • Page 62: Headlight Aim

    3. INSPECTION/ADJUSTMENT PEOPLE/PEOPLE S 250 HEADLIGHT AIM Turn the ignition switch ON. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting bolt. Headlight Aim Adjusting Bolt CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually.
  • Page 63: Brake System

    3. INSPECTION/ADJUSTMENT PEOPLE/PEOPLE S 250 Radiator Cap Remove the front cover. Remove the radiator cap. Remove the drain bolt to drain the coolant and tilt the scooter to the right and the coolant will drain more easily. Drain the coolant in the reserve tank.
  • Page 64: Nuts/bolts/fasteners

    3. INSPECTION/ADJUSTMENT PEOPLE/PEOPLE S 250 NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. Pressure Gauge WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages.
  • Page 65: Lubrication System

    4. LUBRICATION SYSTEM PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ LUBRICATION SYSTEM ________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM --------------------------------------------------------- 4-1 SERVICE INFORMATION----------------------------------------------------------------------- 4-2 TROUBLESHOOTING --------------------------------------------------------------------------- 4-2 ENGINE OIL/OIL FILTER ----------------------------------------------------------------------- 4-3 OIL PUMP REMOVAL---------------------------------------------------------------------------- 4-4 OIL PUMP DISASSEMBLY --------------------------------------------------------------------- 4-4 OIL PUMP INSPECTION ------------------------------------------------------------------------ 4-5...
  • Page 66 4. LUBRICATION SYSTEM PEOPLE/PEOPLE S 250 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Pump...
  • Page 67: Lubrication System Diagram

    4. LUBRICATION SYSTEM PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x The maintenance of lubrication system can be performed with the engine installed in the frame. x Drain the coolant before starting any operations. x Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
  • Page 68: Engine Oil/oil Filter

    4. LUBRICATION SYSTEM PEOPLE/PEOPLE S 250 Oil Dipstick ENGINE OIL/OIL FILTER x Place the scooter upright on level ground for engine oil level check. x Run the engine for 2 3 minutes and check the oil level after the engine is stopped for 2 3 minutes.
  • Page 69: Oil Pump Removal

    4. LUBRICATION SYSTEM PEOPLE/PEOPLE S 250 Bolts OIL PUMP REMOVAL First drain the coolant. Remove the right crankcase cover. ( Ö 10-3) Remove the A.C. generator starter driven gear. ( Ö 10-3) Remove the attaching bolt and oil separator cover.
  • Page 70: Oil Pump Inspection

    4. LUBRICATION SYSTEM PEOPLE/PEOPLE S 250 Pump Body Outer Rotor OIL PUMP INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.25mm replace if over Outer Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.20mm replace if over Inner Rotor Measure the rotor end-to-pump body clearance.
  • Page 71: Oil Pump Installation

    4. LUBRICATION SYSTEM PEOPLE/PEOPLE S 250 Hole Screw Pump Cover Install the pump cover by aligning the hole in the cover with the dowel pin. Tighten the screw to secure the pump cover. Make sure that the pump shaft rotates freely without binding.
  • Page 72: Engine Removal/installation

    5. ENGINE REMOVAL/INSTALLATION PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION ________________________________________________________________________________ SERVICE INFORMATION----------------------------------------------------------------------- 5-1 ENGINE REMOVAL------------------------------------------------------------------------------- 5-2 ENGINE INSTALLATION ------------------------------------------------------------------------ 5-5 ENGINE HANGER REMOVAL ----------------------------------------------------------------- 5-4...
  • Page 73: Service Information

    5. ENGINE REMOVAL/INSTALLATION PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal.
  • Page 74: Engine Removal

    5. ENGINE REMOVAL/INSTALLATION PEOPLE/PEOPLE S 250 ENGINE REMOVAL Drain the coolant. ( Ö3-9) Remove the met-in box, carrier. ( Ö2-6 ) Remove the frame body cover, center cover and rear fender A together. ( Ö2-6 ) Remove the exhaust muffler. ( Ö2-10 ) Disconnect all of the A.C.
  • Page 75 5. ENGINE REMOVAL/INSTALLATION PEOPLE/PEOPLE S 250 Engine Oil Pressure Water Hoses Switch Wire Water Ducts Disconnect the engine oil pressure switch wire. Loosen the water hose bands to disconnect water hoses from the water ducts. Disconnect the secondary air tube from the secondary air inlet tube.
  • Page 76 5. ENGINE REMOVAL/INSTALLATION PEOPLE/PEOPLE S 250 Rear Shock Absorber Bolts Remove the left rear shock absorber. Remove the right rear shock absorber lower mount bolts. Remove the right rear shock absorber. Remove the rear wheel nut. Disconnect the rear brake fluid tube from the guide.
  • Page 77: Engine Installation

    5. ENGINE REMOVAL/INSTALLATION PEOPLE/PEOPLE S 250 Remove the engine mounting bolt and pull out the engine. ENGINE INSTALLATION Reverse the “REMOVAL” procedures. Apply grease onto the O-rings, oil seals and bush). Engine Mounting Bolt Nuts Nuts ENGINE HANGER REMOVAL Remove met-in box and carrier. ( Ö2-6 ) Remove the body cover, center cover and rear fender A together.
  • Page 78 5. ENGINE REMOVAL/INSTALLATION PEOPLE/PEOPLE S 250 Inspect the engine hanger bushings and stopper Bushing rubber for wear or damage. INSTALLATION Reverse the “REMOVAL” procedures. Apply grease onto the bush.
  • Page 79: Cylinder Head/valves

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER HEAD/VALVES ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 6- 1 SERVICE INFORMATION----------------------------------------------------------------------- 6- 2 TROUBLESHOOTING --------------------------------------------------------------------------- 6- 3 CYLINDER HEAD COVER REMOVAL ------------------------------------------------------ 6- 4 CAMSHAFT REMOVAL-------------------------------------------------------------------------- 6- 4 CYLINDER HEAD REMOVAL------------------------------------------------------------------ 6- 6...
  • Page 80: Schematic Drawing

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING...
  • Page 81: Service Information

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. x When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
  • Page 82: Troubleshooting

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 TROUBLESHOOTING x The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler x Compression too low...
  • Page 83: Cylinder Head Cover Removal

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 Bolts CYLINDER HEAD COVER REMOVAL Remove the met-in box, carrier. ( Ö 2-6) Remove the body cover, center cover and rear fender A. ( Ö 2-6) Disconnect the secondary air inlet tube connector and breather hose (air cleaner).
  • Page 84 6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 Camshaft Holder Remove the camshaft holder. Dowel Pins Cam Chain Remove the dowel pins. Remove the camshaft gear from the cam chain to remove the camshaft. Camshaft Gear CAMSHAFT INSPECTION Check each cam lobe for wear or damage.
  • Page 85: Cylinder Head Removal

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 Valve Rocker Arms CAMSHAFT HOLDER DISASSEMBLY Remove the valve rocker arms. Rocker Arm Shafts Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage.
  • Page 86: Cylinder Head Disassembly

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 Cylinder Dowel Pins Remove the dowel pins and cylinder head gasket. Remove the cam chain guide. Remove all gasket material from the cylinder head mating surface. Be careful not to drop any gasket material into the engine.
  • Page 87: Cylinder Head Assembly

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 Straight Edge INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. Service Limit: 0.05mm repair or replace if...
  • Page 88: Cylinder Head Installation

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 Plastic Hammer Tap the valve stems gently with a plastic hammer to firmly seat the cotters. Be careful not to damage the valves. Cylinder Head Cylinder Dowel Pins CYLINDER HEAD INSTALLATION Install the cam chain guide.
  • Page 89: Camshaft Installation

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 Camshaft Gear Cam Chain CAMSHAFT INSTALLATION Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the right crankcase cover. Keep the round hole on the camshaft gear...
  • Page 90: Cylinder Head Cover Installation

    6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250 Tensioner Screw Turn the cam chain tension screw counter clockwise to release it. Bolts O-ring Apply engine oil to a new O-ring and install it. Tighten the cam chain tension cap screw. Be sure to install the gasket into the groove properly.
  • Page 91: Cylinder/piston

    7. CYLINDER/PISTON PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER/PISTON ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 7-1 SERVICE INFORMATION----------------------------------------------------------------------- 7-2 TROUBLESHOOTING --------------------------------------------------------------------------- 7-2 CYLINDER REMOVAL --------------------------------------------------------------------------- 7-3 PISTON REMOVAL ------------------------------------------------------------------------------- 7-3 PISTON INSTALLATION ------------------------------------------------------------------------ 7-7 CYLINDER INSTALLATION -------------------------------------------------------------------- 7-7...
  • Page 92: Schematic Drawing

    7. CYLINDER/PISTON PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING...
  • Page 93: Service Information

    7. CYLINDER/PISTON PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x The cylinder and piston can be serviced with the engine installed in the frame. x When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.
  • Page 94: Cylinder Removal

    7. CYLINDER/PISTON PEOPLE/PEOPLE S 250 Dowel Pins Cylinder Head Gasket Cylinder CYLINDER REMOVAL Remove the cylinder head. ( Ö chapter 6) Remove the dowel pins and cylinder head gasket. Remove the water hose from the cylinder. Water Hose Remove the cam chain guide.
  • Page 95 7. CYLINDER/PISTON PEOPLE/PEOPLE S 250 Inspect the piston, piston pin and piston rings. Remove the piston rings. x Take care not to damage or break the piston rings during removal. Clean carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.
  • Page 96 7. CYLINDER/PISTON PEOPLE/PEOPLE S 250 Measure the piston pin O.D. Service Limit: 16.96mm replace if below Measure the piston O.D. x Take measurement at 9mm from the bottom and 90q to the piston pin hole. Service Limit: 72.60mm replace if below Measure the piston-to-piston pin clearance.
  • Page 97 7. CYLINDER/PISTON PEOPLE/PEOPLE S 250 Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 17.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston.
  • Page 98: Piston Installation

    7. CYLINDER/PISTON PEOPLE/PEOPLE S 250 PISTON INSTALLATION Remove any gasket material from the crankcase surface. x Be careful not to drop foreign matters into the crankcase. Piston Pin Clip “IN” Mark Install the piston, piston pin and a new piston pin clip.
  • Page 99 7. CYLINDER/PISTON PEOPLE/PEOPLE S 250 Install the cam chain guide. x Insert the tab on the cam chain guide into the cylinder groove. Cam Chain Guide Gasket Dowel Pin Install the cylinder head gasket and dowel pins. Connect the water hose to the cylinder.
  • Page 100: Drive And Driven Pulleys/v- Belt

    8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS/V-BELT ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 8- 1 SERVICE INFORMATION----------------------------------------------------------------------- 8- 2 TROUBLESHOOTING --------------------------------------------------------------------------- 8- 2 LEFT CRANKCASE COVER ------------------------------------------------------------------- 8- 3 DRIVE PULLEY ------------------------------------------------------------------------------------ 8- 4...
  • Page 101: Drive And Driven Pulleys/v-belt

    8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING...
  • Page 102: Service Information

    8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x The drive pulley, clutch and driven pulley can be serviced with the engine installed. x Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
  • Page 103: Left Crankcase Cover

    8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Air Tube LEFT CRANKCASE COVER REMOVAL Remove the met-in box and carrier. ( Ö2-6 ) Remove the body cover, center cover and rear fender A together. ( Ö2-6 ) Disconnect the belt air tube from the frame...
  • Page 104: Drive Pulley

    8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Air Tube Connect the drive belt air tube to frame. Universal Holder DRIVE PULLEY Drive Pulley Face DRIVE PULLEY FACE REMOVAL Remove the left crankcase cover. ( Ö8-3 ) Hold the drive pulley using a universal holder and remove the drive face nut and washer.
  • Page 105 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Drive Pulley Collar MOVABLE DRIVE FACE ASSEMBLY Remove the pulley face, clutch outer, driven pulley and belt. ( Ö 8-4)) Remove the movable drive face assembly. Remove the drive pulley collar.
  • Page 106 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Measure the movable drive face bushing assembly I.D. Service Limit: 27.13mm replace if over Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface.
  • Page 107 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Ramp Plate Install the ramp plate. Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSPECTION Inspect the clutch outer for wear or damage. Measure the clutch outer I.D.
  • Page 108 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Clutch Lining Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY DISASSEMBLY Lock Nut Wrench Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor.
  • Page 109 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Movable Driven Face Guide Roller Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Guide Roller Pin O-ring Remove the oil seal from the movable driven Oil Seal face.
  • Page 110 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 40.06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play.
  • Page 111 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Press a new needle bearing into the driven face. Circlips CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. x Keep grease off the clutch linings. Retainer Plate...
  • Page 112 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 CLUTCH ASSEMBLY Circlips Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips.
  • Page 113 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Guide Roller Pin Guide Roller Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face.
  • Page 114 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Drive Pulley Collar INSTALLATION Install the movable drive face assembly and drive pulley collar onto the crankshaft. Movable Drive Face Assembly Driven Pulley and Out Drive Pulley Collar Lay the drive belt on the driven pulley.
  • Page 115 8. DRIVE AND DRIVEN PULLEYS/ V-BELT PEOPLE/PEOPLE S 250 Install the left crankcase cover. ( Ö 8-3) 8-15...
  • Page 116: Final Reduction

    9. FINAL REDUCTION PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FINAL REDUCTION ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 9-1 SERVICE INFORMATION----------------------------------------------------------------------- 9-2 TROUBLESHOOTING --------------------------------------------------------------------------- 9-2 FINAL REDUCTION DISASSEMBLY -------------------------------------------------------- 9-3 FINAL REDUCTION INSPECTION ----------------------------------------------------------- 9-3 FINAL REDUCTION ASSEMBLY ------------------------------------------------------------- 9-6...
  • Page 117: Schematic Drawing

    9. FINAL REDUCTION PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING...
  • Page 118: Service Information

    9. FINAL REDUCTION PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x The servicing operations of this section can be made with the engine installed. x When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.
  • Page 119: Final Reduction Disassembly

    9. FINAL REDUCTION PEOPLE/PEOPLE S 250 Bolts FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. ( Ö 2-10) Remove the rear brake caliper. ( Ö 15-3) Remove the right rear shock absorber. ( Ö 15-7) Remove the rear fork. ( Ö 15-6) Remove the rear wheel.
  • Page 120 9. FINAL REDUCTION PEOPLE/PEOPLE S 250 Inspect the final gear and final shaft for wear, damage or seizure. Drive Shaft and Gear Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage.
  • Page 121 9. FINAL REDUCTION PEOPLE/PEOPLE S 250 Drive Shaft Bearing BEARING REPLACEMENT (TRANSMISSION CASE COVER) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Bearing Remover Drive new bearings into the transmission case cover.
  • Page 122: Final Reduction Assembly

    9. FINAL REDUCTION PEOPLE/PEOPLE S 250 Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Pilot FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Drive Shaft Put the final gear on the left crankcase.
  • Page 123 9. FINAL REDUCTION PEOPLE/PEOPLE S 250 Countershaft Install the countershaft and gear into the left crankcase. Final Shaft Install the final shaft into the final gear and transmission case. Final Gear Gasket Install the dowel pins and a new gasket.
  • Page 124 9. FINAL REDUCTION PEOPLE/PEOPLE S 250 Bolts Install the transmission case cover. Install and tighten the transmission case cover bolts. Install the clutch outer/driven pulley. Install other removed parts in the reverse order of removal. Transmission Case Cover Oil Check Bolt Hole/Filler After installation, fill the transmission case with the specified oil.
  • Page 125: 10. A.c. Generator/starter Clutch

    10. A.C. GENERATOR/STARTER CLUTCH PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 10-1 SERVICE INFORMATION----------------------------------------------------------------------- 10-2 TROUBLESHOOTING --------------------------------------------------------------------------- 10-2 RIGHT CRANKCASE COVER REMOVAL-------------------------------------------------- 10-3 STATOR REMOVAL ------------------------------------------------------------------------------ 10-3 FLYWHEEL REMOVAL -------------------------------------------------------------------------- 10-4 STARTER CLUTCH ------------------------------------------------------------------------------ 10-4...
  • Page 126: Schematic Drawing

    10. A.C. GENERATOR/STARTER CLUTCH PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING 10-1...
  • Page 127: Service Information

    10. A.C. GENERATOR/STARTER CLUTCH PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x All servicing operations and inspections in this section can be made with the engine installed. x Drain the coolant before removing the right crankcase cover. x Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.)
  • Page 128: Right Crankcase Cover Removal

    10. A.C. GENERATOR/STARTER CLUTCH PEOPLE/PEOPLE S 250 Water Pump Cover RIGHT CRANKCASE COVER REMOVAL Disconnect the water hoses from the water pump cover. ( Öchapter 5 ) Disconnect the water hoses from the right crankcase cover. Remove the nine bolts attaching the right crankcase cover and the cover.
  • Page 129: Flywheel Removal

    10. A.C. GENERATOR/STARTER CLUTCH PEOPLE/PEOPLE S 250 Spring Oil Through Remove the oil through and spring. Flywheel Flywheel Holder FLYWHEEL REMOVAL Hold the flywheel with a flywheel holder and remove the flywheel nut and washer. Special Flywheel holder E021 Remove the flywheel with a flywheel puller.
  • Page 130 10. A.C. GENERATOR/STARTER CLUTCH PEOPLE/PEOPLE S 250 Shaft Starter Idle Gear Remove the starter idle gear and shaft. Bolts OIL PUMP REMOVAL Remove the attaching bolts and oil separator cover. Oil Separator Cover Oil Pump Driven Gear Circlip Pry the circlip off and remove the oil pump driven gear, then remove the oil pump drive chain.
  • Page 131 10. A.C. GENERATOR/STARTER CLUTCH PEOPLE/PEOPLE S 250 Bolts Remove the two oil pump bolts to remove the oil pump. Oil Pump INSPECTION Inspect the starter driven gear for wear or damage. Measure the starter driven gear I.D. and O.D. Service Limits: I.D.
  • Page 132 10. A.C. GENERATOR/STARTER CLUTCH PEOPLE/PEOPLE S 250 Arrow Mark Oil Pump INSTALLATION Install oil pump and tighten the two bolts. Make sure that the pump shaft rotates freely. The arrow of oil pump is upside. Bolts Cam Chain Install cam chain.
  • Page 133: Flywheel Installation

    10. A.C. GENERATOR/STARTER CLUTCH PEOPLE/PEOPLE S 250 Starter Idle Gear Shaft Install the starter idle gear and shaft. Starter Driven Gear Install the starter driven gear onto the crankshaft. Flywheel FLYWHEEL INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel.
  • Page 134: Stator Installation

    10. A.C. GENERATOR/STARTER CLUTCH PEOPLE/PEOPLE S 250 Screws Screws STATOR INSTALLATION Install the A.C. generator stator on the right crankcase cover and secure it with the three bolts. Install the pulser coil on the right crankcase cover and secure it with the two screws.
  • Page 135: 11. Crankcase/crankshaft

    11. CRANKCASE/CRANKSHAFT PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CRANKCASE/CRANKSHAFT ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 11-1 SERVICE INFORMATION----------------------------------------------------------------------- 11-2 TROUBLESHOOTING --------------------------------------------------------------------------- 11-2 CRANKCASE SEPARATION------------------------------------------------------------------- 11-3 CRANKSHAFT INSPECTION ------------------------------------------------------------------ 11-4 CRANKCASE ASSEMBLY ---------------------------------------------------------------------- 11-5 11-0...
  • Page 136: Schematic Drawing

    11. CRANKCASE/CRANKSHAFT PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING 11-1...
  • Page 137: Service Information

    11. CRANKCASE/CRANKSHAFT PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. x When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces.
  • Page 138: Crankcase Separation

    11. CRANKCASE/CRANKSHAFT PEOPLE/PEOPLE S 250 Bolt CRANKCASE SEPARATION Remove the three right crankcase attaching bolts. Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase. x Never use a driver to pry the crankcase mating surfaces apart.
  • Page 139: Crankshaft Inspection

    11. CRANKCASE/CRANKSHAFT PEOPLE/PEOPLE S 250 CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.6mm replace if over Measure the connecting rod small end I.D. Service Limit: 17.06mm replace if over 11-4...
  • Page 140: Crankcase Assembly

    11. CRANKCASE/CRANKSHAFT PEOPLE/PEOPLE S 250 Measure the crankshaft runout. Service Limit: 0.10mm replace if over Measure the crankshaft bearing play. Play Service Limits: Play Axial : 0.20mm replace if over Radial : 0.05mm replace if over Axial Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces.
  • Page 141 11. CRANKCASE/CRANKSHAFT PEOPLE/PEOPLE S 250 Left Crankcase Crankshaft Place the left crankcase down and install the crankshaft into the left crankcase. x Avoid damaging the oil seal. x Apply grease to the lip of the oil seal. Gasket Install the two dowel pins and a new gasket.
  • Page 142: 12. Cooling System

    12. COOLING SYSTEM PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ COOLING SYSTEM ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 12- SERVICE INFORMATION----------------------------------------------------------------------- 12- TROUBLESHOOTING --------------------------------------------------------------------------- 12- COOLING SYSTEM TESTING----------------------------------------------------------------- 12- RADIATOR ------------------------------------------------------------------------------------------ 12- WATER PUMP ------------------------------------------------------------------------------------- 12- THERMOSENSOR -------------------------------------------------------------------------------- 12- 14 THERMOSTAT ------------------------------------------------------------------------------------- 12- 15...
  • Page 143: 12. Cooling System

    12. COOLING SYSTEM PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING 12-1...
  • Page 144: Service Information

    12. COOLING SYSTEM PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. x The engine must be cool before servicing the cooling system.
  • Page 145 425cc 975cc -44.5 Cautions for Using Coolant: x Use coolant of specified mixing rate. (The mixing rate of 425cc KYMCO SIGMA coolant concentrate + 975cc distilled water is 30%.) x Do not mix coolant concentrate of different brands. x Do not drink the coolant which is poisonous.
  • Page 146 12. COOLING SYSTEM PEOPLE/PEOPLE S 250 COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Radiator Tester Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. Apply water to the cap sealing surface before testing.
  • Page 147: Radiator

    12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Radiator Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off. Carefully straighten any bent fins.
  • Page 148 12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Radiator Nuts Remove the two bolts and two nuts on the radiator. Remove the radiator. Bolts Fan/Shroud RADIATOR DISASSEMBLY Remove the three bolts and then remove the fan/shroud from the radiator. Bolts Battery Check fan motor by battery.
  • Page 149 12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Thermostatic Switch CHECK THERMOSTATIC SWITCH When coolant temperature lower then 88~92 the thermostatic switch OFF. When coolant temperature over 88~92 the thermostatic switch ON. Radiator Fan/Shroud Install the fan shroud on the radiator with the three bolts.
  • Page 150 12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Radiator Nuts RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and two nuts. Bolts Thermostatic Switch Upper Hose Connect the upper and lower hoses and secure them with hose bands.
  • Page 151: Water Pump

    12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
  • Page 152 12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Mechanical Seal Impeller Inspect the mechanical (water) seal and seal washer for wear or damage. The mechanical seal and seal washer must be replace as a set. Seal Washer (Porcelain) Bolts WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover.
  • Page 153 12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Water Pump Assembly Remove the water pump shaft outer bearing. Inner Bearing Water Pump Assembly MECHANICAL SEAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside. Mechanical Seal (Water Seal)
  • Page 154 12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Outer Bearing WATER PUMP SHAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside. Water Pump Assembly Snap Ring Water Pump Shaft Install the water pump shaft and shaft inner bearing into the waster pump assembly.
  • Page 155 12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Impeller Mechanical Seal WATER PUMP/IMPELLER INSTALLATION When the mechanical seal is replaced, a new seal washer must be installed to the impeller. Seal Washer (Porcelain) Impeller (Left Hand Threads) Install the impeller onto the water pump shaft.
  • Page 156: Thermosensor

    12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Thermosensor THERMOSENSOR THERMOSENSOR REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire THERMOSENSOR INSPECTION...
  • Page 157: Thermostat

    12. COOLING SYSTEM PEOPLE/PEOPLE S 250 Thermostat THERMOSTAT Water Hose Bolt THERMOSTAT REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire from the thermosensor.
  • Page 158 12. COOLING SYSTEM PEOPLE/PEOPLE S 250 THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water Thermostat temperature to check its operation. Technical Data Thermometer Begins to open 80r2 Full-open Valve lift 3.5 4.5mm...
  • Page 159: Fuel System/carburetor/fuel Pump Fuel Tank

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FUEL SYSTEM/CARBURETOR/FUEL PUMP ________________________________________________________________________________ FUEL SYSTEM-------------------------------------------------------------------------------------13- 1 SCHEMATIC DRAWING-------------------------------------------------------------------------13- 2 OPERATION OF CARBURETOR JETS -----------------------------------------------------13- 3 SERVICE INFORMATION-----------------------------------------------------------------------13- 5 CARBURETOR REMOVAL ---------------------------------------------------------------------13- 7 VACUUM CHAMBER DISASSEMBLY-------------------------------------------------------13- 7...
  • Page 160: Fuel System/carburetor/fuel Pump

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK FUEL SYSTEM 13-1...
  • Page 161: Schematic Drawing

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK SCHEMATIC DRAWING 13-2...
  • Page 162: Operation Of Carburetor Jets

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK OPERATION OF CARBURETOR JETS LOW SPEED Venturi (slightly opened throttle valve) Air Bleed HolesÆ Mixture……. Low Speed Air Inlet Fuel in Float ChamberÆ Slow Jet ---------------------- Low Speed Small Jet Holes 2.MIDDLE SPEED...
  • Page 163 13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK FUEL PUMP CONSTRUCTION: The fuel pump adopted for this model is a fuel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve.
  • Page 164: Service Information

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK SERVICE INFORMATION GENERAL INSTRUCTIONS x When working with gasoline, keep away from sparks and flames. x Note the locations of O-rings when disassembling and replace them with new ones during assembly.
  • Page 165 13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK TROUBLESHOOTING Engine does not start Engine idles roughly, stalls or runs poorly x No fuel in tank x Incorrect idle speed x Restricted fuel line x Rich mixture x Too much fuel getting to cylinder...
  • Page 166: Carburetor Removal

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK Auto Bystarter Fuel Tube T.P.S CARBURETOR REMOVAL Remove the met-in box. Disconnect the fuel tube at the carburetor. Disconnect the auto bystarter wire. Disconnect the throttle position sensor wire. Auto Bystarter Wire T.P.S Wire...
  • Page 167 13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK Screws Remove the two vacuum chamber cover screws and the cover. Vacuum Chamber Cover Spring Remove the compression spring and vacuum piston. Vacuum Piston Diaphragm Vacuum Piston Remove the needle holder, spring and jet needle from the piston.
  • Page 168: Float Chamber Disassembly

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK Float Chamber FLOAT CHAMBER DISASSEMBLY Remove the three float chamber screws and the float chamber. Screws Float Remove the float pin, float and float valve. Float Valve Float Pin Float Valve...
  • Page 169 13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK JETS/SCREWS REMOVAL x Before removing the pilot screw, turn the pilot screw clockwise until it seats lightly and record the rotating turns. Do not force the pilot screw against its seat to avoid seat damage.
  • Page 170: Auto Bystarter Inspection/removal

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK AUTO BYSTARTER INSPECTION /REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 14-20: (10 minutes minimum after stopping the engine) If the reading is not within the limit, replace the auto bystarter with a new one.
  • Page 171: Air Cut-off Valve (a.c.v.)

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks, wear or damage. If any faulty part is found, replace the auto bystarter with a new one. Bystarter Needle...
  • Page 172 13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK CARBURETOR BODY CLEANING Blow compressed air through all passages of the carburetor body. x Make sure that no fuel jet is clogged. O-ring Install the O-ring onto the air-cut-off valve body securely.
  • Page 173 13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK Screws ACCELERATING PUMP DISASSEMBLY Remove the two accelerating pump cover screws and accelerating pump cover. Remove the spring and accelerating pump diaphragm. Diaphragm Cover INSPECTION Inspect the accelerating pump diaphragm for cracks, damage or deterioration.
  • Page 174: Float Chamber Assembly

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK Main Jet Slow Jet FLOAT CHAMBER ASSEMBLY Install the main jet. Install the slow jet. Install the pilot screw. x Be sure to record the rotating turns when it is removed.
  • Page 175: Float Level Inspection

    Measure the float level at the location of the main jet (just contacting the float valve). Float Level: 18.5r1.0mm : 18r1.0mm(PEOPLE S 250) Replace the float if the level is incorrect. Check the operation of the float and then reinstall the float chamber.
  • Page 176: Carburetor Installation

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK Check the heater with battery. If the heater is getting hot, means the heater without problem, otherwise the heater has to be changed. Heater Air Cleaner Connecting Tube Band Intake Manifold Band CARBURETOR INSTALLATION Tighten the drain screw.
  • Page 177: Fuel Pump Removal/disassembly

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK Vacuum Tube Outlet Tube FUEL PUMP REMOVAL Remove met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Disconnect the fuel pump inlet, outlet and vacuum tubes.
  • Page 178: Fuel Pump Inspection

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK Diaphragm FUEL PUMP INSPECTION Inspect the fuel pump diaphragms A and B for damage. Inspect each gasket for damage. Gaskets Relief Valve Outlet Suction Valve Inspect the suction valve, outlet valve and relief valve in the fuel pump body for damage, cracks or foreign matters.
  • Page 179: Fuel Pump Installation

    13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK Vacuum Tube Outlet Tube FUEL PUMP INSTALLATION Install the fuel pump and secure it with the two nuts. Connect the fuel pump inlet, outlet and vacuum tubes. Install the met-in box and carrier.
  • Page 180 13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK Fuel Unit Wire Connector Tube to Fuel Filler Disconnect the fuel unit wire connector. Remove the fuel tube between the fuel tank and the fuel filler. Disconnect the fuel vapor tube.
  • Page 181 13. FUEL SYSTEM/CARBURETOR/ PEOPLE/PEOPLE S 250 FUEL PUMP/ FUEL TANK FUEL STRAINER REMOVAL Remove the right side cover. Remove the fuel strainer from the fuel line. Fuel Strainer INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air.
  • Page 182: Steering Handlebar/front Wheel/front Brake/front

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ________________________________________________________________________________ SCHEMATIC DRAWING-------------------------------------------------------------------------14- 1 SERVICE INFORMATION-----------------------------------------------------------------------14- 2 TROUBLESHOOTING ---------------------------------------------------------------------------14- 3 STEERING HANDLEBAR -----------------------------------------------------------------------14- 4 FRONT WHEEL------------------------------------------------------------------------------------14- 5...
  • Page 183: Schematic Drawing

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SCHEMATIC DRAWING 14-1...
  • Page 184: Service Information

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS x Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
  • Page 185: Troubleshooting

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling x Excessively tightened steering stem top x Bent rim cone race x Loose front axle x Broken steering balls x Bent spoke plate...
  • Page 186: Steering Handlebar

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. ( Ö 2-3) Remove the front and rear brake master cylinder attaching bolts. Bolts Throttle Cable Remove the four screws attaching the right and left handlebar switches.
  • Page 187: Front Wheel

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Throttle Cable Lubricate the throttle grip front end with grease and then install the throttle grip. Connect the throttle cable to the throttle grip. Install the right and left handlebar switches and tighten the screws.
  • Page 188 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over Collar FRONT WHEEL BEARING Remove the side collar and dust seal.
  • Page 189 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Driver Handle Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. x Do not allow the bearings to tilt while driving them in.
  • Page 190: Front Brake

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Holder Bolts FRONT BRAKE BRAKE MASTER CYLINDER REMOVAL Remove the handlebar covers. ( Ö 2-3) First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector.
  • Page 191 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75mm Measure the brake master cylinder piston O.D. Service Limit: 12.64mm Before assembly, inspect the lst and 2nd rubber cups for wear.
  • Page 192 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Stop Switch “UP” Mark Wire Connector Place the brake master cylinder on the handlebar and install the holder with the “up” mark facing up. Also align the punch mark with the holder joint seam.
  • Page 193 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper.
  • Page 194 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Service Limit: 25.30mm Check the caliper cylinder for scratches or wear and measure the cylinder bore.
  • Page 195 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts Install the brake caliper to the shock absorber and tighten the two bolts. Torque: 29 35N-m Connect the brake fluid tube with the attaching bolt and two sealing washers to the brake caliper and tighten the fluid tube bolt.
  • Page 196: Front Shock Absorber

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Upper Mount Bolts FRONT SHOCK ABSORBER REMOVAL Remove the front cover. ( Ö 2-5) Remove the front fender cover A and B. ( Ö 2- Remove the front wheel. ( Ö 14-5) Remove the front brake caliper.
  • Page 197: Front Fork

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Lock Nut Socket FRONT FORK REMOVAL Remove the handlebar covers. ( Ö 2-3) Remove the steering handlebar. ( Ö 14-4) Remove the front cover. ( Ö 2-5) Remove the front leg shield. ( Ö 2-8) Remove the front fender cover A and B.
  • Page 198 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPLE/PEOPLE S 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race.
  • Page 199: 15. Rear Brake/rear Fork/rear

    15. REAR BRAKE/REAR FORK/REAR PEOPLE/PEOPLE S 250 WHEEL/REAR SHOCK ABSORBER ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 15-1 SERVICE INFORMATION----------------------------------------------------------------------- 15-2 TROUBLESHOOTING --------------------------------------------------------------------------- 15-2 REAR BRAKE -------------------------------------------------------------------------------------- 15-3 REAR FORK ---------------------------------------------------------------------------------------- 15-6...
  • Page 200 15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING 15-1...
  • Page 201 15. REAR BRAKE/REAR FORK/REAR PEOPLE/PEOPLE S 250 WHEEL/REAR SHOCK ABSORBER SERVICE INFORMATION GENERAL INSTRUCTIONS x When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. x During servicing, keep oil or grease off the brake pads and brake disk.
  • Page 202 15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER PEOPLE/PEOPLE S 250 Fluid Tube Bolt REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler. ( Ö 2-10) Remove the rear brake fluid tube bolt and disconnect the brake fluid tube.
  • Page 203 15. REAR BRAKE/REAR FORK/REAR PEOPLE/PEOPLE S 250 WHEEL/REAR SHOCK ABSORBER Compressed Air Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston.
  • Page 204 15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER PEOPLE/PEOPLE S 250 ASSEMBLY Clean all removed parts. Apply silicon grease to the piston and oil seal. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out.
  • Page 205 15. REAR BRAKE/REAR FORK/REAR PEOPLE/PEOPLE S 250 WHEEL/REAR SHOCK ABSORBER Fluid Tube Bolt INSTALLATION Install the brake caliper to the rear fork and tighten the two bolts. Torque: 29 35N-m Connect the brake fluid tube to the brake caliper and install fluid tube bolt, copper washers and tighten the fluid tube bolt.
  • Page 206 15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER PEOPLE/PEOPLE S 250 REAR WHEEL REMOVAL Remove the exhaust muffler. ( Ö 2-10) Remove the rear brake caliper. ( Ö 15-3) Remove the rear fork. ( Ö 15-6) Remove the rear axle collar.
  • Page 207 15. REAR BRAKE/REAR FORK/REAR PEOPLE/PEOPLE S 250 WHEEL/REAR SHOCK ABSORBER INSTALLATION Install the rear shock absorbers in the reverse order of removal. Torque: Upper Mount Bolt: 35 45N-m Lower Mount Bolt: 35 45N-m ADJUSTABLE REAR CUSHION To suit scooter behaviour to load condition rear cushion could be adjusted in spring preload.
  • Page 208 15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER PEOPLE/PEOPLE S 250 Disconnect the breather hose from air cleaner and keep air cleaner up to adjust rear left cushion with wrench. Breather Hose Wrench Air Cleaner 15-9...
  • Page 209: 16. Battery/charging System

    16. BATTERY/CHARGING SYSTEM PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ BATTERY/CHARGING SYSTEM ________________________________________________________________________________ CHARGING SYSTEM LAYOUT --------------------------------------------------------------- 16-1 SERVICE INFORMATION----------------------------------------------------------------------- 16-2 TROUBLESHOOTING --------------------------------------------------------------------------- 16-3 BATTERY-------------------------------------------------------------------------------------------- 16-4 CHARGING SYSTEM ---------------------------------------------------------------------------- 16-5 A.C. GENERATOR INSPECTION------------------------------------------------------------- 16-5 REGULATOR/RECTIFIER INSPECTION --------------------------------------------------- 16-6 16-0...
  • Page 210 16. BATTERY/CHARGING SYSTEM PEOPLE/PEOPLE S 250 CHARGING SYSTEM LAYOUT Fuse Battery Regulator/Rectifier A.C. Generator CHARGING CIRCUIT 16-1...
  • Page 211 16. BATTERY/CHARGING SYSTEM PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention x The battery can be charged and discharged repeatedly.
  • Page 212 16. BATTERY/CHARGING SYSTEM PEOPLE/PEOPLE S 250 SPECIAL TOOLS Flywheel holder E021 Flywheel puller E003 TROUBLESHOOTING No power Intermittent power x Dead battery x Loose battery cable connection x Disconnected battery cable x Loose charging system connection x Fuse burned out...
  • Page 213 16. BATTERY/CHARGING SYSTEM PEOPLE/PEOPLE S 250 Battery Cover Screw BATTERY Remove the seat and met-in box. ( Ö 2-3) Remove the battery cover screw and the battery cover. Remove the battery. First disconnect the battery negative (-) cable and then the positive (+) cable.
  • Page 214 16. BATTERY/CHARGING SYSTEM PEOPLE/PEOPLE S 250 Red Wire CHARGING SYSTEM CURRENT TEST Use a fully charged battery (12.8V min.) to check the charging system. Warm up the engine before taking readings. Connect an electric tester across the battery terminals. Disconnect the red wire from the fuse terminal and connect an ammeter between the red wire lead and the fuse terminal.
  • Page 215 16. BATTERY/CHARGING SYSTEM PEOPLE/PEOPLE S 250 A.C. Generator Stator Pulser Coil A.C. GENERATOR REMOVAL A.C. generator removal ( Ö 10-3) A.C. generator installation ( Ö 10-6) Right Crankcase Cover Bolts REGULATOR/RECTIFIER INSPECTION Remove the met-in box. ( Ö 2-6) Remove the regulator/rectifier wire coupler.
  • Page 216: 17. Ignition System

    17. IGNITION SYSTEM PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ IGNITION SYSTEM ________________________________________________________________________________ IGNITION SYSTEM LAYOUT ------------------------------------------------------------------ 17-1 SERVICE INFORMATION----------------------------------------------------------------------- 17-2 TROUBLESHOOTING --------------------------------------------------------------------------- 17-2 SPARK PLUG -------------------------------------------------------------------------------------- 17-3 IGNITION COIL INSPECTION ----------------------------------------------------------------- 17-3 A.C. GENERATOR INSPECTION------------------------------------------------------------- 17-4 IGNITION UNIT RESISTANCE INSPECTION --------------------------------------------- 17-4...
  • Page 217: Ignition System Layout

    17. IGNITION SYSTEM PEOPLE/PEOPLE S 250 IGNITION SYSTEM LAYOUT Ignition Switch Ignition Unit Ignition Coil A.C. Generator Pulser Coil IGNITION CIRCUIT IGNITION UNIT 17-1...
  • Page 218: Troubleshooting

    17. IGNITION SYSTEM PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x Check the ignition system according to the sequence specified in the Troubleshooting. ( Ö 1-28) x The ignition system adopts ignition unit and the ignition timing cannot be adjusted.
  • Page 219: Spark Plug

    17. IGNITION SYSTEM PEOPLE/PEOPLE S 250 Ignition Coil SPARK PLUG For spark plug inspection and adjustment, refer to page 3-5. IGNITION COIL INSPECTION Remove the seat and met-in box. ( Ö 2-6) Remove the ignition coil Ignition Coil Primary Coil...
  • Page 220: A .c. Generator Inspection

    17. IGNITION SYSTEM PEOPLE/PEOPLE S 250 A .C. GENERATOR INSPECTION EXCITER COIL/PULSER COIL INSPECTION This test is performed with the stator installed in the engine. Remove the seat and met-in box. ( Ö 2-6) Disconnect the A.C. generator connector. Measure the exciter coil resistance between the black/white wire terminal and ground.
  • Page 221 17. IGNITION SYSTEM PEOPLE/PEOPLE S 250 Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing. Use of an improper tester in an improper range may give false readings. x In this table, “Needle swings then returns”...
  • Page 222: 18. Starting System

    18. STARTING SYSTEM PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ STARTING SYSTEM ________________________________________________________________________________ STARTING SYSTEM LAYOUT ---------------------------------------------------------------- 18-1 SERVICE INFORMATION----------------------------------------------------------------------- 18-2 TROUBLESHOOTING --------------------------------------------------------------------------- 18-2 STARTER MOTOR-------------------------------------------------------------------------------- 18-3 STARTER CLUTCH INSPECTION ----------------------------------------------------------- 18-6 STARTER RELAY INSPECTION-------------------------------------------------------------- 18-6 18-0...
  • Page 223: Starting System Layout

    18. STARTING SYSTEM PEOPLE/PEOPLE S 250 STARTING SYSTEM LAYOUT Stop Switch Starter Button Starter Relay Starter Motor STARTING CIRCUIT Relay 18-1...
  • Page 224: Troubleshooting

    18. STARTING SYSTEM PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x The removal of starter motor can be accomplished with the engine installed. x For the starter clutch removal, refer to page 10-3. x After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
  • Page 225 18. STARTING SYSTEM PEOPLE/PEOPLE S 250 STARTER MOTOR REMOVAL x Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
  • Page 226 18. STARTING SYSTEM PEOPLE/PEOPLE S 250 Check for continuity between pairs of the commutator segments and there should be continuity. Also, make a continuity check between individual commutator segments and the armature shaft. There should be no continuity. STARTER MOTOR CASE CONTINUITY...
  • Page 227: Starter Motor

    18. STARTING SYSTEM PEOPLE/PEOPLE S 250 Bushing Check if the needle bearing in the front cover turns freely and has no excessive play. Replace if necessary. Check the dust seal for wear or damage. Dust Seal ASSEMBLY Apply grease to the dust seal in the front cover.
  • Page 228: Starter Clutch Inspection

    18. STARTING SYSTEM PEOPLE/PEOPLE S 250 STARTER CLUTCH INSPECTION Refer to pages 10-4 and 10-5 for the starter clutch removal, inspection and installation. STARTER RELAY INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground.
  • Page 229 19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH/TEMPERATURE GAUGE/ INSTRUMENTS/LIGHTS ________________________________________________________________________________ ELECTRICAL EQUIPMENT LAYOUT -------------------------------------------------------19-1 SERVICE INFORMATION-----------------------------------------------------------------------19-2 TROUBLESHOOTING ---------------------------------------------------------------------------19-2 SWITCHES------------------------------------------------------------------------------------------19-3 HORN INSPECTION------------------------------------------------------------------------------19-5 FUEL UNIT ------------------------------------------------------------------------------------------19-5 THERMOSTATIC SWITCH ---------------------------------------------------------------------19-6 TEMPERATURE METER------------------------------------------------------------------------19-6 INSTRUMENTS ------------------------------------------------------------------------------------19-7...
  • Page 230: Electrical Equipment Layout

    19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS PEOPLE/PEOPLE S 250 ELECTRICAL EQUIPMENT LAYOUT Starter Button Engine Stop Switch Headlight Stop Switches Switch Passing Ignition Switch Dimmer Switch Turn Signal Switch Horn Button Thermostati Fuel Unit c Switch Horn Heater Control Unit...
  • Page 231: Troubleshooting

    19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS x After installation of each switch, a continuity check must be performed. A continuity check can usually be made without removing the part from the motorcycle. TESTING INSTRUMENT...
  • Page 232: Switches

    19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS PEOPLE/PEOPLE S 250 SWITCHES IGNITION SWITCH INSPECTION Remove the frame front covers. ( Ö 2-5) Disconnect the ignition switch wire couplers. Check for continuity between the wire terminals. Color Black/W Green Black hite Position...
  • Page 233 19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS PEOPLE/PEOPLE S 250 HORN BUTTON INSPECTION Remove the handlebar front covers. ( Ö 2-3) Disconnect the horn wire couplers. Depress the horn button and check for continuity between the wire terminals. Br/L Color Light Green...
  • Page 234 19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS PEOPLE/PEOPLE S 250 Horn HORN INSPECTION Remove the front cover. ( Ö 2-5) Disconnect the horn wire couplers. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals.
  • Page 235: Thermo-static

    19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS PEOPLE/PEOPLE S 250 THERMOSTATIC SWITCH INSPECTION Remove the front covers. ( Ö 2-5) Start and run the engine to make the water temperature reaches 85 check if the cooling fan motor operates. Lower the water temperature to 85 check if the fan motor stops.
  • Page 236 19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS PEOPLE/PEOPLE S 250 THROTTLE POSTTION SENSOR Unit:K: 0~5±1 0~5±1 T.P.S. Screws INSTRUMENTS REMOVAL Remove the handlebar rear cover. ( Ö 2-4) Remove the three screws under instruments. Remove the instruments from the handlebar rear cover.
  • Page 237: Side Stand Switch

    19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS PEOPLE/PEOPLE S 250 Rubber Boot FRONT POSITION LIGHT /HEADLIGHT BULB REPLACEMENT Remove the handlebar front cover. ( Ö 2-3) Remove the position bulb socket by turning them counterclockwise. Remove the bulb and replace with new one.
  • Page 238: Heater Wiring Diagram

    19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS PEOPLE/PEOPLE S 250 HEATER WIRING DIAGRAM 19-9...
  • Page 239 . EXHAUST EMISSION CONTROL SYSTEM PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM ________________________________________________________________________________ SCHEMATIC DRAWING..................18-1 EXHAUST EMISSION CONTROL SYSTEM FUNCTION ........18-1 TROUBLESHOOTING .................... 18-2 SERVICE INFORMATION..................18-2 SECONDARY AIR CLEANER ................18-3 AIR INJECTION CUT-OFF VALVE (A.I.C.V.)............18-3 REED VALVE......................
  • Page 240 . EXHAUST EMISSION CONTROL SYSTEM PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING Air Injection Carburetor Cut-off Valve Vacuum Reed Valve Secondary Secondary Air Air Cleaner Cleaner Into Hole EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re-combustion by means of exhaust pulsation so as to minimize the exhaust emission.
  • Page 241 . EXHAUST EMISSION CONTROL SYSTEM PEOPLE/PEOPLE S 250 TROUBLESHOOTING High CO at idle speed 1. Damaged or clogged reed valve 2. Damaged or clogged air injection cut-off valve 3. Clogged air cleaner Backfiring at sudden deceleration 1. Damaged reed valve (malfunction) 2.
  • Page 242 . EXHAUST EMISSION CONTROL SYSTEM PEOPLE/PEOPLE S 250 Secondary Air Cleaner / A.I.C.V. SECONDARY AIR CLEANER / AIR INJECTION CUT-OFF VALVE (A.I.C.V.) REMOVAL Remove the seat. ( Ö 2-4) Remove the body cover. Disconnect the secondary air cleaner /(A.I.C.V) connecting tube.
  • Page 243 . EXHAUST EMISSION CONTROL SYSTEM PEOPLE/PEOPLE S 250 Reed Valve Cover Cylinder Head Cover REED VALVE REMOVAL Remove the frame body cover. Remove the floor-foot cover. Disconnect the secondary air inlet tube connector. Remove the reed valve cover three bolts and two secondary air outlet tube bolts.

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